arther dailey
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I can relate to this, I make and sell garden statue s /bird baths ,you know the sort of thing you see at garden centres, well I get antique pieces, make master moulds/working moulds,then cast from them..yes you make a mistake sometimes I really hate it,as every casting will have that error,the one thing I have learned is to 99% of my customers its invisible, to the point where something I consider really bad sells like hot cakes,where as something that is technically best you can get and even I am happy with is a none seller.
My dad used to say horses for courses,if making a 16 foot truck body 1/16" doesnt matter but regrinding the crank Two thou matters,I often think of that to keep things in perspective.Arther
My dad used to say horses for courses,if making a 16 foot truck body 1/16" doesnt matter but regrinding the crank Two thou matters,I often think of that to keep things in perspective.Arther

What I cut off must have been added by whoever rebuilt the car some years ago, there are four in total and they connect the floor pan to a fibreglass outer sill. The material they were badly made from seems to be some form of embossed aluminium roofing/cladding and the rusty bolts had to be ground off. A simple job to replicate four new ones and bolt them in place, nobody will see them and at least they will all be the same unlike the ones I cut off, job done move on.
) aluminium isn't the right material for under the car with steel bolts so mild steel will be better. Captive nuts would be nice to save fiddling about with washers and two spanners so Rivnuts it is then. What if the Rivnuts go rusty and one day someone has to grind the bolts off then make new brackets? Best make the whole lot stainless so there's no rusty Rivnuts. Spotweld two thickness's together and tap M5. I've run out of M5 stainless penny washers! No problem, make four clamping plates and linish the ends to a nice radius. An M6 bolt and penny washer to go through the floor and we're done. I've run out of M6 stainless penny washers! No problem, make four stud plates from stainless and Tig weld them together then Sikaflex to the floor pan to save pulling the carpets up if they need to be undone. Radius all the corners on the linisher because you can then deburr everything.


I was with your train of thought every step of the process. 


